Optically Insulated Electronic Control Module for Vehicle Power Networks

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Solution Overview

Problem

In electrical supply systems for motor vehicles, there is a need to ensure that information exchange channels between different voltage networks do not allow for power current transmission, particularly between a high-voltage power network and a lower-voltage service network, while maintaining efficient control and communication.

Innovation Solution

An electronic control unit with a first module supplied by the high-voltage power network and a second module supplied by the lower-voltage service network, utilizing an optically insulated communication channel to prevent current passage, with light-emitting diodes and photoreceptors integrated on separate substrates to facilitate two-way communication.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If an optically insulated communication channel is used to prevent power current transmission between networks, then electrical insulation and safety are improved, but device complexity increases due to the need for separate substrates and optical components

Engineering Contradiction:

Improveelectrical insulationVSAvoidcommunication channel structure

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

An optically insulated communication channel acts as an intermediary between the first and second electronic modules, allowing information exchange while preventing electrical current transmission. The optical medium (light-emitting diodes and photoreceptors) mediates the communication without creating an electrical connection, thus resolving the contradiction between enabling communication and maintaining electrical insulation.

Inventive Principle:

Principle #24Intermediary (Mediator)

Solution Approach 2:

The electronic control unit is segmented into two separate substrates: a first substrate for the high-voltage power network and a second substrate for the low-voltage service network. This segmentation physically separates the electrical domains while maintaining communication capability through optical means, addressing both the insulation requirement and the communication need.

Inventive Principle:

Principle #1Segmentation

2Reliability

If separate substrates with optical components are used for communication, then power current isolation is improved, but manufacturing complexity and cost increase

Engineering Contradiction:

Improvecurrent isolationVSAvoidassembly process

Core Design Contradiction:

ReliabilityVSEase of manufacture

Solution Approach 1:

The light-emitting diodes and photoreceptors are integrated directly onto the substrate surfaces, merging the communication components with the electronic modules. This integration reduces the number of separate parts and assembly steps compared to using discrete optical couplers, thereby improving ease of manufacture while maintaining current isolation.

Inventive Principle:

Principle #5Merging (Combining)

3Productivity

If optical communication components are integrated on substrates, then information exchange efficiency is improved, but device complexity increases

Engineering Contradiction:

Improveinformation exchange efficiencyVSAvoidmodule structure

Core Design Contradiction:

ProductivityVSDevice complexity

Solution Approach 1:

The optical communication system replaces traditional electrical communication mechanisms (such as wired connections or transformers) with optical fields. This substitution enables faster information exchange efficiency while the integration of components on substrates manages the structural complexity, balancing both requirements.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Applied Scientific Principles

This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.

Function Achieved in This Case

Ensures secure and efficient information exchange between the power and service networks without power current transmission, maintaining high voltage insulation and enabling effective control of the electrical supply system.

Implementation Method 1

at least one first light-emitting diode and at least one first photoreceptor are added onto the first substrate opposite openings in this intermediate layer, corresponding respectively to at least one second photoreceptor and at least one second light-emitting diode added onto the second substrate

Methodology Applied

Scientific EffectLight-emitting diode: Light Emitting Diode

Implementation Method 2

Methodology Applied

Scientific EffectPhotoreceptor: Photoelectric Effect

Data Source

PatentUS10214165B2Electrical supply system for a motor vehicle, and corresponding electronic control module

Publication Date: 2019.02.26 VALEO EQUIP ELECTRIC MOTEUR

AI summary

The electrical supply system according to the invention is of the type comprising, on the one hand, an electrical power network having a first voltage electrically connecting first items of equipment comprising an electrical motor/generator, an inverter/rectifier and a first electrical energy store, and, on the other hand, an electrical service network having a second voltage that is less than the first voltage electrically connecting second items of equipment comprising a second electrical energy store, an electronic control unit controlling the energy transfers between the power network and the service network by means of at least one reversible DC/DC converter The electronic unit comprises a first electronic module supplied by the power network exchanging information with the first items of equipment, and a second electronic module supplied by the service network exchanging information with the second items of equipment and electrically insulated from the first module.